Overview

Overview
Applications

Medical Implants
Aerospace

Arcam Products
Materials

Additive Manufacturing with EBM (Electron Beam Melting)

2012-04-10

2012-04-10

EBM - Electron Beam Melting

Additive Manufacturing (AM) Benefits

Unlock design potential

Reduce time-to-market

Reduce material costs

Reduce machining costs

and

Makes it possible to manufacture parts

with lattice and cellular structures!

2012-04-10

The electron beam gun generates a

high energy beam (up to 3.000 W)

The beam melts each layer of powder

metal to the desired geometry

Extremely fast beam translation with

no moving parts

High beam power -> high build rate

(up to 80 cm3/h) and productivity

Vacuum process -> eliminates impurities

and yields excellent material properties

High process temperature (700 C

for titanium) -> low residual stress
and no need for heat treatment

2012-04-10

The EBM Machine

Medical Implants

EB Gun
Build Chamber

Overview
Applications

Heat Shield

Powder
Container

Medical Implants
Aerospace

Arcam Products
Materials

Powder Rake
Build Platform
Control Unit

2012-04-10

Build Tank

2012-04-10

Benefits with EBM

Trabecular Structures

Implant manufacturing with EBM

Design your unique trademark trabecular structure

Optimize for osseointegration

Freedom in design
Cost-efficient production

With CAD or with a Structure generator software

Excellent material properties

Pore geometry (no limitation)

Pore size (down to ~400 m)
Porosity (up to ~85%)

Competitive manufacturing costs

2012-04-10

EBM

production cost, typical: < 2 /cm3 trabecular structure

2012-04-10

Bio-Compatibility

Implant Categories

Pictures of bone growing into EBM -manufactured

titanium implants with Trabecular Structures

Acetabular cups
Revision cups
Augments
Femoral stems
CMF
Spine
Shoulders
Triflanges
Tibial trays
Femoral knees

In production
with EBM

Courtesy of Professor Peter Thomsen, MD, Dept. of Biomaterials,

University of Gothenburg.

2012-04-10

2012-04-10

10

Production Benefits

Single-step production of solid and porous sections,

with structural continuity between them

All-porous implants possible (augments, wedges, )

High process temperature gives low residual stress,

and no need for heat treatment after the build

No secondary high temperature process to apply the

porous structure that could cause grain growth

2012-04-10

Post-Build Processing

11

2012-04-10

Remove and recycle excess powder

Machine inside with conventional CNC
Clean parts with ultrasonic and solvents
Quality Control with EBM LogStudio

12

CE-certified & FDA-cleared Implants

Fixa Ti-Por Acetabular Cup

CE-certified acetabular cups with integrated

Trabecular Structures since 2007
Implants with FDA clearance since 2010
> 20,000 cups implanted
25% of the global production of cups with advanced
porous coatings is now manufactured with EBM

Adler Ortho, IT
2007

Lima-Lto, IT
2007

CE-certified since 2007

Exactech, US
2010

2012-04-10

Courtesy of Adler Ortho s.p.a.

13

2012-04-10

14

DELTA TT Acetabular Cup

CE-certified since 2007

DELTA TT Revision Cup

Material:
Ti6Al4V
Build time: 16 cups in
10 hours

CE-certified since 2007

Courtesy of Lima-Lto s.p.a.

Material:
Ti Grade 2
Build time: 4 cups in
16 hours

Courtesy of Lima-Lto s.p.a.

2012-04-10

15

2012-04-10

16

FUSE Lumbar PLIF Cage

CE-certified since 2009

Material:
Ti6Al4V
Build time: 16 cups in
10 hours

Material:

Summary
Ti Grade 2

EBM lets you design and produce unique trademark

Trabecular Structures with minimum investment

EBM offers a unique single-step production

method for solid and porous implants

EBM provides structural continuity between solid

and porous sections, and requires no heat treatment

EBM is a proven and cost-efficient technology,

with thousands of implanted CE-certified products

Courtesy of Advanced Medical Technologies AG

2012-04-10

17

2012-04-10

18

Aerospace

Overview
Applications

AM Benefits in Aerospace
The Aerospace industrys fundamental characteristics are

Medical Implants
Aerospace

Arcam Products
Materials

EBM is the ultimate Additive Manufacturing solution

for the aerospace industry with its

19

High productivity
Excellent material properties
Ability to process new materials

Several aerospace applications in the pipeline

2012-04-10

Extreme requirements on product performance

Geometric design complexity
Extensive use of Ti alloys
Use of exotic materials

All major engine OEMs have ongoing EBM initiatives

First application in series production during 2012

2012-04-10

20

AM Drivers in Aerospace

Freedom in Design

Material:
Size:
Weight:
Build time:

Optimize geometry for weight savings

Optimize geometry for improved function
Brackets (weight), Vane segments (function), Filters (function)

-TiAl
8 x 12 x 325 mm
0,5 kg
7 hours / blade

Materials Savings

Turbine Blades

Buy-To-Fly ratios of 15-20 are common in Aerospace

95% of the material is machined away as scrap

For EBM the Buy-To-Fly ratio is close to 1

Materials Flexibility

Many alloys with unique characteristics are difficult to cast and forge

EBM has demonstrated that it can be used to process such alloys

Courtesy of Avio S.p.A.

2012-04-10

21

2012-04-10

22

Aerospace Prototype

Rocket Engine Impeller

Material:
Ti6Al4V
Size:
180 x 300 mm
Weight:
5,5 kg
Build time: 40 hours

Material:
Size:
Weight:
Build time:

Ti6Al4V ELI
140 x 80 mm
2,5 kg
16 hours

Courtesy of CalRAM, Inc.

2012-04-10

23

2012-04-10

24

Arcam Products

Overview
Applications

Arcam A1

Medical Implants
Aerospace

Arcam Products
Materials

For Implant production,

in titanium and CoCr

Build size 200 x 200 x 180 mm

Full EBM MultiBeam
technology, providing

2012-04-10

25

200 x 200 x 350 mm and

300 x 200 mm

Two alternative build tanks

(tall and wide)
Full EBM MultiBeam
technology, providing

27

2012-04-10

Training & Maintenance

28

Arcam Powder Metals

Support & Maintenance

agreements to maximize
use of machines, incl.

> 95% recovery of

unmelted powder
Minimal dust generation
for safe operation
Closed circuit until powder
recovery is completed

High productivity
Smooth surfaces

2012-04-10

26

Powder Recovery System

For Aerospace production,

in titanium alloys
Large build volume

High productivity
Smooth surfaces

2012-04-10

Arcam A2

Application support
Periodic maintenance
Spare parts
Emergency visits
Support hot-line

Pre-alloyed powder
Powder fractions selected for safe operation and handling
Verified material properties
Chemical composition in accordance with applicable standards
Optimized process parameters

Training packages to
ensure operator skills

2012-04-10

Basic training
Advanced training

29

2012-04-10

30

Materials

Overview
Applications

Materials Strategy

Medical Implants
Aerospace

Arcam Products
Materials

2012-04-10

31

Arcam's customers range from companies in the aerospace and

medical implant industries who use their EBM systems for
production, to universities and institutes that focus on research.

Arcam's materials strategy is to supply our industrial

customers with the metals they use in their production.

We simultaneously make it possible for our research-oriented

customers to work with other materials, by providing additional
training that enables them to use EBM with these materials.

2012-04-10

32

Other Materials in EBM

Materials Portfolio

With the high power available (up to 3.000 W) the EBM process
can melt any powdered metal with a melting point temperature
up to 3.400 C (e.g. W), allowing an extensive range of materials.

The materials currently supplied by Arcam are:

Titanium alloy Ti6Al4V (Grade 5)

Titanium alloy Ti6Al4V ELI (Grade 23)
Titanium CP (Grade 2)
CoCr alloy ASTM F75

For these materials Arcam has

Established a validated powder supply chain

Optimized process themes that match powder quality
Verified material properties of the built material

2012-04-10

33

Design for function

Integrated trabecular structures
for improved bone ingrowth
Light-weight structures

Tool steel (e.g. H13)

Aluminium (e.g. 6061)
Hard metals (e.g. NiWC)
Copper (e.g. GRCop-84)
Beryllium (e.g. AlBeMet)
Amorphous metals
Niobium
Invar

34

Thank you for your attention!

Arcam AB
Kroksltts Fabriker 27A
SE-431 37 Mlndal, Sweden
Phone: +46 31 710 32 00
Web site: www.arcam.com
E-mail: info@arcam.com

Controlled microstructure
Better than cast
Compliant with applicable
standards

Arcam - CAD to Metal

Cost-Efficient Production

2012-04-10

Stainless steel (e.g. 316L)

Contact

Excellent Material Properties

Superalloys (e.g. Inconel 625 & 718)

Freedom in Design

Titanium aluminide (-TiAl)

2012-04-10

EBM - Core Benefits

Arcam has tested and has customers who use a range of other
materials in their EBM machines, including but not limited to:

High productivity
Material recycling

35

2012-04-10

36